Metal door assembly

ABSTRACT

A formed sheet metal rectangular-shaped frame is positioned between two sheet metal side panels which may be embossed to provide the appearance of small wood panels. The frame includes an elongated frame member for each edge of the door, and each frame member has two outwardly facing parallel spaced channel portions integrally connected by a center web portion. Extruded plastic trim members cover the top and side frame members and include longitudinally extending hook-shaped leg portions which project into the channel portions and snap-fit onto inwardly formed edge portions of the side panels. A foam insulation material is expanded between the side panels and also serves to space the side panels laterally from the frame to form a thermal barrier. The side trim members are interrupted or notched to receive the door hinges and a latch bolt housing which seat on the web portions of the corresponding frame members. A generally U-shaped elongated door seal is secured to the frame member which extends along the bottom of the door.

United States Patent [19] Imperial et al.

[ 1 May 2'7, 1975 1 METAL DOOR ASSEMBLY [73] Assignee: Johnson Sheet Metal Works Corp,

Richmond, Ind.

[22] Filed: Nov. 19, 1973 [21] Appl. No.: 416,883

[52] US. Cl. 49/501; 49/470; 49/482; 2/624 [51] Int. Cl E06b 3/16; E04c 2/34 [58] Field of Search 49/501, 503, 470, DIG. 1, 49/D1G. 2; 52/615, 619, 620, 623, 624

[56] References Cited UNITED STATES PATENTS 3,153,817 10/1964 Pease, Jr. 52/619 3,273,287 9/1966 Pease, Jr..... 49/470 X Primary ExaminerPhilip C. Kannan Attorney, Agent, or Firm-Jacox & Meckstroth [5 7] ABSTRACT A formed sheet metal rectangular-shaped frame is positioned between two sheet metal side panels which may be embossed to provide the appearance of small wood panels. The frame includes an elongated frame member for each edge of the door, and each frame member has two outwardly facing parallel spaced channel portions integrally connected by a center web portion. Extruded plastic trim members cover the top and side frame members and include longitudinally extending hook-shaped leg portions which project into the channel portions and snap-fit onto inwardly formed edge portions of the side panels. A foam insulation material is expanded between the side panels and also serves to space the side panels laterally from the frame to form a thermal barrier. The side trim members are interrupted or notched to receive the door hinges and a latch bolt housing which seat on the web portions of the corresponding frame members. A generally U-shaped elongated door seal is secured to the frame member which extends along the bottom of the door.

12 Claims, 10 Drawing Figures METAL DOOR ASSEMBLY BACKGROUND OF THE INVENTION In the construction of metal doors such as, for example, the doors disclosed in US. Pat. Nos. 2,297,609, 3,153,817, 3,273,287, and 3,455,078, it has been found desirable to provide for a thermal barrier between the sheet metal skins or side panels of the door in addition to providing for a door which is rigid and will remain flat and not warp with changes in temperature and humidityv It is also desirable for a metal door to be constructed so that the hinges may be mounted on either door edge and in a recessed manner so that the hinges are flush with the outer edge surface of the door.

Similarly, it is desirable to provide for mounting the lock or latch bolt on either side of the door and to position the mounting flange for the bolt housing so that the flange is flush with the corresponding edge surface of the door. In addition to the above features, it is desirable for the metal door to include an adjustable threshold sealing member along the bottom of the door and to provide for quick and simplified assembly and installation.

SUMMARY OF THE INVENTION The present invention is directed to an improved metal door assembly which provides all of the desirable features mentioned above and, in addition, provides for using sheet metal side panels each of which may be drawn to form a series of rectangular impressions for producing the appearance of a conventional wood panel door construction. In the illustrated embodiment of the invention, the door assembly is constructed without any wood and includes a metal frame. The frame is formed by roll forming a metal strip to produce a pair of parallel spaced U-shaped channel portions which are integrally connected by a center web portion. The metal frame extends along each edge of the door, and the channel portions of the frame receive inwardly projecting edge portions of the sheet metal side panels.

An expanded plastics foam insulation material fills the cavity defined between the side panels and also extends into narrow spaces defined between the side panels and the metal frame to form a thermal barrier. Extruded plastics trim members cover the channel portions of the frame members extending along the vertical edges and top of the door. Each trim member includes integral hook-shaped longitudinally extending leg portions which project into the channel portions of the frame and snap-fit onto the inwardly formed edge portion of the side panels. The trim members are notched or interrupted to receive the hinges and a door latch bolt assembly, and an extruded plastics door sweep or seal with flexible sealing lips, is adjustably connected to the metal frame member along the bottom of the door.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is an elevational side view ofa metal door constructed in accordance with the present invention;

FIG. 2 is a fragmentary section taken generally on the line 2-2 of FIG. 1;

FIG. 3 is an exploded perspective view of a top corner portion of the door and illustrating the joining of the ends of the frame member;

FIG. 4 is a fragmentary perspective view as would be seen on the line 44 of FIG. 1;

FIG. 5 is a fragmentary section taken generally on the line 55 of FIG. 1;

FIG. 6 is another fragmentary section taken generally on the line 6-6 of FIG. 1;

FIG. 7 is a further fragmentary section taken generally on the line 7-7 of FIG. 1 and illustrating the support of a door sweep or sealing member;

FIG. 8 is a fragmentary section similar to FIG. 5 and taken generally on the line 88 of FIG. 1;

FIG. 9 is a fragmentary section similar to FIG. 7 and illustrating the seal formed by the sealing member be tween the bottom of the door and a door threshold; and

FIG. 10 is a fragmentary perspective view of a bottom portion ofa door assembly and showing a modified form of a door sweep or sealing member.

DESCRIPTION OF THE PREFERRED EMBODIMENT The sheet metal door assembly illustrated in FIG. 1 includes a rectangular-shaped metal frame formed by an elongated frame member 10 extending along each edge of the door. The frame members are constructed by roll forming a sheet metal strip, and each frame member includes a pair of parallel spaced U-shaped channel portions 12 integrally connected by a flat center web portion 14. The outer longitudinal edges of the channel portions 12 are formed inwardly to produce opposing lip portions 16 which are located slightly in wardly from the web portion 14. The rectangular frame is formed by notching and bending the roll-formed strip for three of the corners of the door, and the adjacent mitered ends 17 (FIG. 3) of the strip are joined together at the fourth upper corner of the door by a formed sheet metal angle bracket 18 and a set ofPop rivets 19.

A pair of opposing rectangular side panels 25 are formed of sheet metal and are preferably either finishcoated with a baked-on-enamel or epoxy paint or are precoated with a durable plastics material. The side panels 25 are stamped or drawn to form a series of rectangular frame-like recesses or impressions 27, 28 and 29 to provide each panel 25 with the appearance of a paneled wood door. However, it is to be understood that the recesses or impressions 27-29 may be omitted for flush door assemblies.

The top and longitudinal edge portions of each side panel 25 are formed inwardly by two right angles to produce a corresponding flange portion 31 and another flange or tab portion 32. The tab portions 32 may be continuous along the side and top edges of each side panel 25 or may be interrupted to form a series of spaced tabs. As shown in FIGS. 2-8, the tab portions 32 of each side panel 25 contact or engage the ends of the adjacent lip portions 16 of the frame members 10 and project inwardly into the cavities defined by the channel portions 12 of the frame 10.

The bottom edge portion of each side panel 25 is secured to the bottom frame member 10 by a doublesided adhesive tape 34 having a thickness of about onesixteenth inch. The width of the flange portions 31 of each side panel 25 is somewhat greater than the width of the lip portions 16 of the frame members 10 to form a narrow slot-like space 36 between each of the side panels 25 and the frame members 10 around the periphery of the frame. The outer surface of each flange portion 31 of each side panel 25, is positioned flush with the outer surface of the web portion 14 of the corresponding frame member l0, as illustrated in FIGS. 5-8.

An expanded froth-type polymeric foam insulation material 38 fills the entire cavity defined within the metal frame members between the side panels 25 and extends outwardly into the space between the channel portions 12 of the frame members 10 and the narrow spaces 36 defined between the frame members 10 and side panels 25. Preferably, the insulation material 38 consists of a rigid polyurethane foam which is expanded between the side panels 25 after the panels are assembled onto the frame members 10 and while the panels 25 are confined between rigid back-up form members or platens (not shown).

Referring to FIGS. 2-4, an elongated semi-rigid trim member 40 extends along one vertical edge of the door and across the top of the door. The trim member 40 has a width substantially equal to the spacing between the side panels 25 and is extruded from a plastics material such as a semi-rigid polyvinyl chloride. Each trim member 40 has a flat outer wall 42, and a set of integral parallel flange portions 44 project inwardly from the wall 42 to engage the corresponding inwardly formed flange portions 31 of the side panels 25. Each trim member 40 also includes an inwardly projecting longitudinally extending integral bead portion 46 which seats against the adjacent web portion 14 of the frame member 10.

A pair of integral hook-shaped leg portions 48 extend longitudinally of the trim member and project into the cavities formed by the channel portions 12 of the adjacent frame member 10. The leg portions 48 also project outwardly under the inner ends of the inwardly projecting tab portions 32 of the side panels 25. The outer wall 42 of each of the trim members 40 is flexed or bowed outwardly to a slightly curved configuration by pinching the flange portions 44 for inserting the leg portions 48 into the channel portions 12 of the adjacent frame member 10. When the outer wall 42 is released, the leg portions 48 snap outwardly under the tab portions 32 (FIGS. 2 and 3), to form a positive rigid connection of the trim member 40 to the frame member 10.

Another elongated trim member 40'(FIGS. 5 and 8) extends along the opposite vertical edge of the door and covers the corresponding frame member 10. The trim member 40 is constructed substantially the same as the trim member 40 and thus the corresponding portions of the trim member are identified with like reference number with the addition of a prime mark. The main difference between the trim member 40 and the trim member 40 is shown in FIG. 5. That is, the outer wall 42' tapers at a slight angle of approximately 3 relative to a reference plane normal to the side panels 25. This slight angle or taper provides a beveled outer edge surface for the outer edge of the door and minimizes the width of the gap defined between this edge of the door and the adjacent door jamb.

Referring to FIG. 6, a set of metal hinges 55 include plates 56 which are mounted on the opposite or inner edge of the door and are secured to the adjacent frame member 10 by a set of screws 57 which thread into holes formed within the channel portions 12 of the frame member. The hinge plates 56 seat on the outer flange portions 31 of the side panels 25 and the web portion 14 of the adjacent frame member 10, and the trim strip 40 is notched or interrupted for each of the hinges 55. Preferably, the flanges 44 of the trim strip 40 have a thickness which is equal to the thickness of the attached hinge plate 56 so that the outer surface of each hinge plate is substantially flush with the outer surface of the wall 42 of the trim member 40.

Referring to FIG. 8, a circular bore 58 is formed within the web portion 14 of the frame member 10 along the outer edge of the door and within the insulation material 38 for receiving a tubular housing 61 which supports a latch bolt 62 projecting from a conventional door lock assembly 65. The latch bolt housing 61 includes a mounting flange 66 which is secured to the web portion 14 of the adjacent frame member 10 by a set of screws 67 positioned above and below the latch bolt 62 and threaded into the web portion 14. If desired, the mounting flange 66 may be tilted slightly by a tapered wedge-like shim 69 so that the outer sur-. face of the mounting flange 66 is substantially flush with the outer tapered surface of the trim member 40'.

As shown in FIGS. 7 and 9, the frame member 10 which extends along the bottom of the door, receives an elongated door sweep or sealing member which is preferably formed as a dual durometer extrusion of a plastics material such as polyvinyl chloride. The sealing member 75 includes a pair of parallel spaced inverted U-shaped channel portions 76 which interfit into the corresponding channel portions 12 of the frame member 10 and are integrally connected by a flat bottom web portion 77. A set of spring-like longitudinally extending flanges 79 are extruded as an integral part of the sealing member 75 and are inclined upwardly to engage the channel portions 12 of the bottom frame member 10. The flanges 79 urge the sealing member 75 downwardly against the heads of a series of spaced retaining screws 81 which arethreaded upwardly into holes formed within the web portion 14 of the bottom frame member 10.

A set of longitudinally extending lips 84 project downwardly from the channel portions 76 of the sealing member 75. The longitudinally extending lips 84 are extruded as an integral part of the sealing member 75 but are formed of a flexible vinyl material as compared with the semi-rigid vinyl material forming the remaining portion of the sealing member 75. As shown in FIG. 9, the sealing member 75 is positioned relative to the bottom of the door by adjusting screws 81 so that when the door is closed, the sealing lips 84 engage the top surface of a threshold 85 which is secured to the floor at the bottom of the doorway. To adjust the position of the sealing member 75 relative to the threshold 85, the door is removed from the hinges 55 in order to have convenient access to the screws 81.

In some installations where it is not convenient to remove the door from the hinges 55, a channel-like door sweep or sealing member (FIG. 10) is attached to the bottom frame member 10 of the door in place of the sealing member 75. The sealing member 90 is also formed of extruded plastics material and includes a substantially flat bottom wall 92 which integrally connects a pair of upwardly projecting side walls or flanges 94. The flanges 94 engage the outer surfaces of the side panels 25 and have a series of longitudinally spaced vertical slots 96 which receive corresponding screws 97 for securing the sealing member 90 to the bottom frame member 10 of the door.

A series of longitudinally extending sealing lips 99 are extruded as an integral part of the sealing member 90, but are formed of a flexible plastics material in the same manner as the sealing lips 84 described above in connection with FIGS. 7 and 9. The sealing member 90 is positioned relative to the door threshold 85 simply by releasing the screws 9'7, adjusting the position of the sealing member 90 and then retightening the screws 97.

From the drawing and the above description it is ap parent that a metal door constructed in accordance with the present invention, provides desirable features and advantages. For example, the assembly of the metal door frame members It) and the metal side panels 25, provides a rigid construction which is not affected by changes in temperature and humidity, and the expanded foam insulation material 38 cooperates to minimize heat and sound transfer. The extension of the insulation material into the narrow spaces 36 between the side panels 25 and the door frame members 10 also provides a thermal barrier so that the frame members 10 do not conduct heat from one side panel 25 to the other side panel 25.

Another important feature is provided by the cooperation of the door frame members 10 and the trim members 40 and 40. That is, the trim members not only provide a cover for the cavities defined by the channel portions 12 of the corresponding frame members 10, the trim members also provide for conveniently mounting the hinges and the flange of the latch bolt housing so that they are flush with the outer corresponding edge surfaces of the door. in addition, the trim members 40 and 40' may be conveniently interchanged to provide either a left hinging or a right hinging door. As mentioned above, the frame member 10 along the bottom of the door, provides for positively retaining the door sweep or sealing member '75 and for adjusting the member within the lower edge portion of the door so that the sealing lips 84 engage the door threshold 85 with the desired flexing as illustrated in FIG. 9.

While the forms of door assemblies herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise forms of door assemblies, and that changes may be made therein without departing from the scope and spirit of the invention as defined in the appended claims.

The invention having thus been described, the following is claimed:

1. An improved metal door assembly comprising a rectangular-shaped metal frame including longitudinally extending parallel metal frame members each having two longitudinally extending parallel spaced channel portions integrally connected by a web portion, said channel portions of each said longitudinal frame member defining two outwardly facing longitudinally extending cavities, each of said channel portions including an inwardly and laterally projected lip portion extending generally flush with said web portion, a set of generally parallel rectangular sheet metal side panels each having outer edge portions formed inwardly and projecting into said cavities for connecting said side panels to said frame, thermal insulation material disposed within said frame between said side panels, a set of elongated trim members extending adjacent said frame members and covering said cavities, and each of said trim members includes a set of longitudinally extending hook-shaped leg portions projecting into said cavities under the corresponding said lip portions for securing said trim members to said frame and said side panels.

2. A metal door assembly as defined in claim 1 wherein said outer edge portions of said side panels project inwardly into the adjacent said cavities beyond the corresponding said lip portions, and said leg portions of each said trim member snap-fit outwardly under said outer edge portions of said side panels.

3. A metal door assembly as defined in claim 1 wherein at least one of said trim members is interrupted to define a space adjacent the corresponding frame member, a hinge assembly including a hinge plate extending into said space, means for securing said hinge plate to said channel portions of the adjacent said frame member, and said one trim member and said hinge plate have substantially the same thickness.

4. A metal door assembly as defined in claim 1 wherein said frame further includes an elongated bottom frame member having two parallel inverted U- shaped channel portions integrally connected by a web portion, a generally U-shaped elongated sealing member projecting into said channel portions and including a plurality of downwardly projecting and longitudinally extending flexible sealing lips, and means for adjusting the vertical position of said sealing member relative to said bottom frame member.

5. A metal door assembly as defined in claim 4 wherein said sealing member includes inverted generally U-shaped portions projecting into said channel portions of said bottom frame member.

6. An improved metal door assembly comprising a rectangular-shaped metal frame including at least one elongated metal frame member having a plurality of longitudinally extending parallel spaced channel portions integrally connected by a web portion, said channel portions of said frame member defining corresponding outwardly facing longitudinally extending parallel spaced cavities, a set of generally parallel rectangular sheet metal side panels each have outer edge portions formed inwardly and projecting into corresponding said cavities for connecting said side panels to said frame member, said web portion of said frame member extending generally flush with said outer edge portions of said side panels, thermal insulation material disposed within said frame between said side panels, an elongated trim member extending adjacent said web portion of said frame member and covering said cavities, said trim member including portions projecting into said cavities, and means for securing said portions of said trim member to said frame member.

7. An improved metal door assembly comprising a rectangular-shaped metal frame including longitudinally extending parallel metal frame members defining outwardly facing longitudinally extending cavities, each of said frame members including a set of inwardly and laterally projecting lip portions disposed in opposing relation, a set of generally parallel rectangular sheet metal side panels each having outer edge portions formed inwardly and projecting into said cavities adjacent said lip portions of said frame members for connecting said side panels to said frame, thermal insulation material disposed within said frame between said side panels, a set of elongated trim members extending adjacent said frame members and covering said cavities, said trim members including portions projecting into said cavities, and means on said portions of said trim members for securing said trim members to said edge portions of said side panels.

8. A metal door assembly as defined in claim 7 wherein at least one of said side panels cooperates with at least one of said frame members to define a narrow space therebetween. and said insulation material extends into said narrow space to provide a thermal barrier between said one side panel and said frame member.

9. A metal door assembly as defined in claim 7 wherein at least one of said trim members includes a substantially flat semi-rigid outer wall portion integrally connecting generally parallel spaced and longitudinally extending leg portions, and each of said leg portions includes a longitudinally extending and laterally outwardly projecting hook portion positioned to snap-fit into engagement with said edge portion of the adjacent said side panel.

10. A metal door assembly as defined in claim 7 wherein at least one of said side panels is spaced laterally of said frame to define a space therebetween, and said insulation material comprises a froth-type polymeric rigid foam material expanded into said space.

11. An improved metal door assembly comprising a rectangular-shaped metal frame including a set of longitudinally extending and a set of laterally extending metal frame members each of said frame members including two longitudinally extending parallel spaced channel portions integrally connected by a web portion, said channel portions of each said frame member defining two longitudinally extending cavities a set of generally parallel rectangular sheet metal side panels each having outer edge portions formed inwardly and projecting into said cavities of at least some of said frame members for connecting said side panels to said frame thermal insulation material disposed within said frame between said side panels, a set of elongated trim members extending adjacent at least some of said frame members and covering the corresponding said cavities, and each of said trim members including a set of longitudinally extending hook-shaped leg portions projecting into said cavities of the corresponding said frame member under the corresponding said edge portions of said side panels.

12. A metal door assembly as defined in claim 11 wherein at least one of said side panels cooperates with at least one said frame members to define a narrow space therebetween, and said insulation material extends into said narrow space to provide a thermal barrier between said one side panel and said frame member. 

1. An improved metal door assembly comprising a rectangularshaped metal frame including longitudinally extending parallel metal frame members each having two longitudinally extending parallel spaced channel portions integrally connected by a web portion, said channel portions of each said longitudinal frame member defining two outwardly facing longitudinally extending cavities, each of said channel portions including an inwardly and laterally projected lip portion extending generally flush with said web portion, a set of generally parallel rectangular sheet metal side panels each having outer edge portions formed inwardly and projecting into said cavities for connecting said side panels to said frame, thermal insulation material disposed within said frame between said side panels, a set of elongated trim members extending adjacent said frame members and covering said cavities, and each of said trim members includes a set of longitudinally extending hook-shaped leg portions projecting into said cavities under the corresponding said lip portions for securing said trim members to said rame and said side panels.
 2. A metal door assembly as defined in claim 1 wherein said outer edge portions of said side panels project inwardly into the adjacent said cavities beyond the corresponding said lip portions, and said leg portions of each said trim member snap-fit outwardly under said outer edge portions of said side panels.
 3. A metal door assembly as defined in claim 1 wherein at least one of said trim members is interrupted to define a space adjacent the corresponding frame member, a hinge assembly including a hinge plate extending into said space, means for securing said hinge plate to said channel portions of the adjacent said frame member, and said one trim member and said hinge plate have substantially the same thickness.
 4. A metal door assembly as defined in claim 1 wherein said frame further includes an elongated bottom frame member having two parallel inverted U-shaped channel portions integrally connected by a web portion, a generally U-shaped elongated sealing member projecting into said channel portions and including a plurality of downwardly projecting and longitudinally extending flexible sealing lips, and means for adjusting thE vertical position of said sealing member relative to said bottom frame member.
 5. A metal door assembly as defined in claim 4 wherein said sealing member includes inverted generally U-shaped portions projecting into said channel portions of said bottom frame member.
 6. An improved metal door assembly comprising a rectangular-shaped metal frame including at least one elongated metal frame member having a plurality of longitudinally extending parallel spaced channel portions integrally connected by a web portion, said channel portions of said frame member defining corresponding outwardly facing longitudinally extending parallel spaced cavities, a set of generally parallel rectangular sheet metal side panels each have outer edge portions formed inwardly and projecting into corresponding said cavities for connecting said side panels to said frame member, said web portion of said frame member extending generally flush with said outer edge portions of said side panels, thermal insulation material disposed within said frame between said side panels, an elongated trim member extending adjacent said web portion of said frame member and covering said cavities, said trim member including portions projecting into said cavities, and means for securing said portions of said trim member to said frame member.
 7. An improved metal door assembly comprising a rectangular-shaped metal frame including longitudinally extending parallel metal frame members defining outwardly facing longitudinally extending cavities, each of said frame members including a set of inwardly and laterally projecting lip portions disposed in opposing relation, a set of generally parallel rectangular sheet metal side panels each having outer edge portions formed inwardly and projecting into said cavities adjacent said lip portions of said frame members for connecting said side panels to said frame, thermal insulation material disposed within said frame between said side panels, a set of elongated trim members extending adjacent said frame members and covering said cavities, said trim members including portions projecting into said cavities, and means on said portions of said trim members for securing said trim members to said edge portions of said side panels.
 8. A metal door assembly as defined in claim 7 wherein at least one of said side panels cooperates with at least one of said frame members to define a narrow space therebetween, and said insulation material extends into said narrow space to provide a thermal barrier between said one side panel and said frame member.
 9. A metal door assembly as defined in claim 7 wherein at least one of said trim members includes a substantially flat semi-rigid outer wall portion integrally connecting generally parallel spaced and longitudinally extending leg portions, and each of said leg portions includes a longitudinally extending and laterally outwardly projecting hook portion positioned to snap-fit into engagement with said edge portion of the adjacent said side panel.
 10. A metal door assembly as defined in claim 7 wherein at least one of said side panels is spaced laterally of said frame to define a space therebetween, and said insulation material comprises a froth-type polymeric rigid foam material expanded into said space.
 11. An improved metal door assembly comprising a rectangular-shaped metal frame including a set of longitudinally extending and a set of laterally extending metal frame members, each of said frame members including two longitudinally extending parallel spaced channel portions integrally connected by a web portion, said channel portions of each said frame member defining two longitudinally extending cavities, a set of generally parallel rectangular sheet metal side panels each having outer edge portions formed inwardly and projecting into said cavities of at least some of said frame members for connecting said side panels to said frame, thermal insulation material disposed within said frame between said side panels, a set of elongaTed trim members extending adjacent at least some of said frame members and covering the corresponding said cavities, and each of said trim members including a set of longitudinally extending hook-shaped leg portions projecting into said cavities of the corresponding said frame member under the corresponding said edge portions of said side panels.
 12. A metal door assembly as defined in claim 11 wherein at least one of said side panels cooperates with at least one said frame members to define a narrow space therebetween, and said insulation material extends into said narrow space to provide a thermal barrier between said one side panel and said frame member. 